Apparatus for catalytic operations



wly 23, 1946. 1 A s` HAMMOND 2,404,574

APPARATUS FOR CATALYTIG OPERATIONS I Filed Nov. 30, 1945 A TTORNE YS .method of producing acetaldehyde by Patented July 23,y v1946l AI'IB-ATUSl FOR CATALYTIC OPERATIONS JohnA. S. Hammond, Glenbrook, Conn., assignor to U. S. Industrial Chemicals, Inc., New York,

' N. Y., a corporation of Delaware Application November 3 This invention relates to apparatus for Vcatalytic operations particularly those in which a. gaseous phase is passed through a shallow catalyst bed to effect the desired reaction. Y In an application Ser. No. 509,124, led November 5, 1943, Frederick R. Balcar has described a oxidation of ethyl alcohol in which a preheated. mixture of ethyl alcohol vapor and air is passed through a shallow catalyst bed consisting of `massive silver in the form of short rods having spacing means integral therewith at a temperature of 30D-400 C. The apparatus hereinafter described is particularly adapted to facilitate the operation of the Balear method. It is, however, equally applicable and useful in other catalytic operations of a similar nature in which the gaseous phase passes through a shallow catalyst bed.' Where the catalyst bed is relatively shallow, that is of the order of two inches in depth, the catalyst offers relatively little resistance to the fiow of gas, and there is therefore very little pressure drop across it. Thus,'in the operation described in the Balcar application, the difference in pressure between the upstream and downstream flows of gas is equivalent to about inches of water or even less. Because of the low pressure drop, inequalities of flow over portions of the bed may be established with resulting detriment to the efficiency of the operation. y

' If the rate of gas flow varies materially through different portions of the catalyst bed, those portions of the catalyst which are subjected to increased rates of flow may become inactive due to the fact that the reaction zone has advanced so close to the lower surface of the catalyst bed as to be incapable of supporting further combustion. The temperature of the remaining portions of the bed will not be materially increased since the temperature is limited by the composition of the inlet gas. The conversion is very considerably lowered and the yield may alsobe decreased. If the areas of increased flow increase substantially in their relation to the area of the entire catalyst bed, the reaction may cease entirely, due to the cooling effect of the gases which do not react, since the degree of preheat is generally considerably below the temperature required to initiate and maintaining the reaction.

It isessential that the downstream as well as the upstream flow of gases be uniform. Any nonuniformity of downstream flow will in turn iniiuence the pressure drop through the catalyst bed and cause a non-uniform flow therethrough. It is evident, therefore, that to maintain continuous and satisfactory operation, the flow must be o, 1943, seriai No. 512,390

' 401mm. (c1. ,z3- 288) 2 uniform on .both sides of and through the catalyst bed.

It is the object of the invention to provideA a simple and effective apparatus which ensures uniform flow of the gaseous phase to, through and from the catalyst bed and consequent improvement in the efficiency of the reaction. ,Y Other objects and advantages of the invention will be apparent as it is better understood by reference to the following specification and accompanying drawing, in which Fig. 1 is a longitudinal section through an apparatus embodying the invention; and Fig. 2 is a section on the line 2-2 of Fig. 1.

I have discovered that uniform ilow of a gas through a shallow catalyst bed can be established and maintained satisfactorily, in spite, of a relatively low pressure drop, if the inlet and outlet 'connections to the catalyst bed are of conical shape having the proper dimensions.V To secure the desired result, the length of the cone on each side of the catalyst bed should be atleast five times'the diameter'of vthe catalyst bed. Thus, for example, with a, bed 18 inches in diameter, the two cones on opposite sides thereof should be approximately 7 feet long, to secure the best results.v Obviously some, Variation from these dimensions is possible, particularly if the full advantages of the invention are not considered es- Y sential. In general, the invention rests upon the fact that by employing a conical inlet and a conical outlet of substantial length, the flow of gas to and from the catalyst bed and through the bed is maintained at a substantially uniform rate, even though the pressure drop is relatively slight. As a result, inequalities of flow through the catalyst bed are avoided and the efficiency of the operation is maintained. Measurements with a Pitot tube have demonstrated the effectiveness of the apparatus in securing the desired uniformity of flow throughout the path of travel of the gases. y

Referring to the drawing,l5 indicates afcatalyst chamber which is preferably circular in crosssection. It is provided with a grid 6 which supports a screen 'l carrying a shallow bed a of the catalyst, for example the silver rivets as described by Balcar. Other catalysts may be employed to facilitate various catalytic reactions in the gaseous phase.

`At the inlet end of the chamber 5, a cone 9 is mounted. As indicated, the cone is of substantial length compared` with the diameter of the catalyst chamber. It is connected to a pipe I0 through which the gas preheated to the desired temperature is introduced.

. operations.

n the opposite side of the catalyst chamber similar cone I I is secured and connected to a pipe I2 through'which the gaseous products are Withdrawn. The chamber 5 and the cones 9 and II may be surrounded bysuitable insulating mate'- rial I3. In the apparatus as described, the entering gasilOWs,atgaxuniform rate ythrcluglrthe QQrle 9 and thecatalysti. and thence through; thegcone I I to the outlet pipe I2.

Theapparatus may be constructed of suitable material, depending upon the'particular reaction" vzone at their bases and approximately five times 1 involved. It should, of course',1be .ofvsuch material as not to affect the reactionljr thevproduction of acetaldehyde from ethyl alcohol; the.. chamber 5 is preferably made of brass or stainlessvzv-Jsterel,'k

which should be coated withl silver inthe form of a sheet or by electroplatingeor spraying'. inlet cone 9; which isat relatively lovvftempera-V ture, may be made conveniently of Ycopper or brass. Thegoutlet cone I I, being'at higher, tem- Y perature, is preferably made ofv brass. Af17he ;gri cl 6 is .also conveniently made of brass, Whichfshould be coated with silver. I p-refertomake thescreen "I ,ofg silver. "These detailsv concerningv materials Aare lmerely by Way'oi'example in.` an apparatus intended toV improve the. efficiency; of aparticular operation. Any material may beiused Whichvrill vwithstand the temperatures'and isjinnocuouswith respect to. the entering.gases vand theA products of vthe reaction, or, in other Wordsgrlo .not` interfere with the. intended reactiongwhich 'isfeiected' by the catalyst used.V

The dimensions may varylwidily, :depending upon the contemplated reaction. j;lior the purpose of converting `ithylyalcoh'ol toacetaldehyde; the

` catalyst "chaniber"v 5 ;may ..have, aninternalfdiameter of 18.r 'inchesand rmay' beapproxiznately: 12

Vinches in length. .The twouconesf 9,Y and. I l are each approximately ."7jy feet in length, Ytapering l from .thecifameterv-ofihe.fcacncnr-chaniberac a diameter .of .about ,.4 inches. 'Such an apparatus isY highly efcie'ntin .the catalyticconyersion of ethyl alcohol. to4 acetaldehydfiand,h asindicated, the. principles may, beE appliedto similar .catalytic Various chang"esamay' be madeV in the dtails vof construction, the materials. usedand thediinensacricing theadvantages thereof. Y

. sions Without Adeparting 5 from the inventionor 1. In an apparatus forrgaseous phase catalytic Y operations, a catalytic zone of substantially uniform cross-sectional area. and of relatively nar- 'row height arranged to receive a relatively shallow catalyst bed, means to support said catalystV bed in said zone, and conduits having portions .substantially, uniformly conial ,extending from the catalyst-zone on ,bathfgsidesafthereof, the cone `shape'di'iortion's of said 'conduits being of sub-v `r,stantially the diameter of the ends of the catalytic said diameter in length. Y Y n 2. VIn an apparatus for gaseous phase catalytic QperatQllS,f-a catalytic zone of substantially uni- .fornncrpss'esectional area and of relatively narrow height arranged to Vreceive a relatively sha1- illow:catalystbedkatsilver coated .grid and a screen "operations, arsilver lined catalytic zone of`sub- Vthegendspf the catalytic. zone, at their, Y. approximately llive, times .saidE diamen-n length.

' staifitially' uniform cross-sectionalarea,"V and of relatiyelyfnarrow; height "arrangedto' receive a relatively *shallow* catalystibed, meansl to'support vsaidcatalyst bed4 in said zone, Yand conduits vhaving y portionsl substantially uniformly conical extending .'.frQm fthe. Catalyst 20.11@ pon '.bO'bhsides thereefrtne ccnehaped; pprtons' of. .Said conduits l,being {o'f substantially the diameter of the; ends ...of ,thecatalyticgzone atv then-bases andV approximately; iiye times;I said diameter yinlength.

.4. VIn an, apparatus. for-.gaseus .phase catalytic operabona aatalyticA zofne of .substantiallyguniy form cross'sectiona1:areafand .0f relatively narrow. .height arraeedgto. receiva relatively. sha1- low catalyst bed, lrn'ean's'jcro'.s'ulvoport' said catalyst bedn. said zone, `andronduits einen-ferrous metal having portions, 51,110.5tantiallyA uniformly Y conical, extending fromthe, Cavrta'lyst:z.one',Y onfborth sides thereof,v thefacone shaped portions -:of said .conduits being of substantially the A diameter of lssgand 

